Disconnect the 2 frame wire connectors from the inverter with converter assembly and protect the electrode and connector parts with insulating tape.

Use a small screwdriver to lift up the green lock pin, then disconnect the connector for the air conditioning inverter.

Disconnect any remaining wiring connectors including the engine main wiring harness.

Remove the mounting bolts and disconnect the MG1 and MG2 power cables. Protect the connector parts with insulating tape.

Remove the 3 mounting bolts and the inverter with converter assembly.

Remove timing chain.

Disconnect associated connectors and wire harnesses.

Remove the fuel pipe clamp.

Disconnect the fuel tube from the fuel delivery pipe. Even if the fuel tube is stuck and cannot be disconnected, do not use any tools. Push and pull the parts with the quick connector pinched to disconnect the tube.

Cover the disconnected fuel tube and fuel delivery pipe with a plastic bag in order to prevent foreign objects from entering them.

Disconnect the radiator inlet hose from the cylinder head.

Disconnect the hoses from the cylinder head as shown in the illustration.

Remove the bolt and disconnect the No. 1 water by-pass pipe.

Disconnect the hoses, remove the bolt and disconnect the oil dipstick guide.

Remove the camshafts.

Fig. Cylinder head bolt loosening sequence-1.5L hybrid engine

Using an 8mm bi-hexagon wrench, loosen the cylinder head bolts in several steps in the proper sequence. Then remove the cylinder head bolts and washer.

CAUTION

When removing the bolt, do not drop the washer into the engine. Removing the cylinder head bolts in the wrong order may cause damage to the cylinder head.

Apply seal packing with a 0.177-0.217 inch (4.5-5.5mm) thickness. Install the cylinder head within 3 minutes of applying seal packing.

Apply a light coat of engine oil to the threads of the cylinder head bolts.

Fig. Cylinder head bolt tightening sequence-1.5L hybrid engine

Fig. Retightening the cylinder head bolts by an additional 90 degrees-1.5L hybrid engine

Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8mm bi-hexagon wrench in the proper sequence to 21 ft. lbs. (29 Nm).

Mark the front of the cylinder head bolt with paint.

Retighten the cylinder head bolts by an additional 90 degrees and then another 90 degrees. Check that the paint mark is now 180 degrees opposite to the front.

Install the camshafts.

Install the oil dipstick guide with the bolt and tighten to 80 inch lbs. (9 Nm). Connect the hose.

Connect the water by-pass pipe with the bolt and tighten to 80 inch lbs. (9 Nm).

Connect the hoses.

Connect the radiator inlet hose.

Push the fuel main tube into the fuel delivery pipe until it makes a "click" sound. If the fuel tube is connected too tightly, apply a light coat of engine oil to the tip of the fuel delivery pipe. After connecting, check that the fuel tube is securely connected by pulling it.

Install the fuel pipe clamp.

Connect all associated connectors and wire harnesses.

Install the timing chain.

On 2002-03 Prius models, while wearing insulating gloves, install the converter and inverter assembly as follows:

While wearing insulating gloves, joint the service plug grip with the HV battery. While pushing the service plug grip to the right, rotate the lever to the right. Slide the lever down to lock the service plug grip in place.